Donaldson BOFA AD 1000 iQ User manual

VER 3.0 –01/2020
AD 1000 iQ
USER MANUAL

Contents
01
02
03
Overview of your extraction system (front)
Overview of your extraction system (back)
Overview of LCD display
1
01
Unpacking and unit placement
3
01
Fume capture methods
02
Connecting to power supply
03
Optional added features
04
Optional added features (cont’d)
(cont’s)
4
01
Turning extractor on / changing display units
02
Setting the airflow
03
Airflow auto adjust (first installation only)
5
01
02
Important safety notes
Safety labels
2
01
02
Cleaning the unit / Pre-filter replacement
Combined filter replacement
6
01
Fault indication / error codes
8
01
Consumables spares / filter disposal
9
01
AD 1000 iQ specifications
10
01
Display features / visual alarms
Visual alarms (cont’d)
7
02
03
USB connectivity / USB upload
04
USB download
05
Information collected by USB
05
Optional added features (cont’d)
(cont’s)

Overview
Company Branding
Standby Button LCD Display Return “enter”
Button
Up / Down
Buttons
Door Latches
Lever/ Filter Location
Brackets
Lockable Castors
Pre Filter
Combined Filter
Lever
Combined Filter
USB Port
Locking Latch
01
1

Overview
Exhaust outlet
Mains Inlet
Signal Cable
(optional)
Mains On/Off
Switch
Motor Cooling Inlet
Motor Cooling
Outlet
Unit Inlet
Castors
Motor Cut
Out Trips
02
1

Real time pre filter
condition
Real time Combined filter
condition
Internal unit temperature 0C / 0F
Motor run hours/
Alarm window
Target airflow set
point
Actual airflow in
CFM or m3/h
Motor status icon
Overview
03
1

Safety Instructions
Important safety notes
Concerning symbols used on the extraction unit and referred
to within this manual.
Danger
Refers to an immediately impending danger. If the danger is
not avoided, it could result in death or severe (crippling)
injury. Please consult the manual when this symbol is
displayed.
Warning
Refers to a possibly dangerous situation. If not avoided it
could result in death or severe injury. Please consult the
manual when this symbol is displayed.
Caution
Refers to a possibly harmful situation. If not avoided,
damage could be caused to the product or something in its
environment.
Important (Refer to manual)
Refers to handling tip and other particularly useful
information. This does not signify a dangerous or harmful
situation. Refer to manual when this symbol is displayed.
Electrical Safety
The unit has been designed to meet the Essential Health
and Safety Requirements of the Machinery Directive
2006/42/EC.
Warning
When working with the pump/motor housing open, Live
230/115 volt mains components are accessible. Ensure that
the rules and regulations for work on live components are
always observed.
Important
To reduce the risk of fire, electric shock or injury:
1. Always isolate the system from the mains power
supply before removing the pump/motor access
panel.
2. Use only as described in this manual.
3. Connect the system to a properly grounded outlet.
Dangers to eyes, breathing and skin
Once used, the filters within the system may contain a
mixture of particulates, some of which may be sub-micron
size. When the used filters are moved it may agitate some of
this particulate, which could get into the breathing zone and
eyes of the operative. Additionally, depending on the
materials being lasered, the particulate may be an irritant to
the skin.
This unit should not be used on processes with sparks of
flammable materials or with explosive dusts and gases,
without implementation of additional precautions.
Caution: When changing used filters always wear a mask,
safety shoes, goggles and gloves.
Carbon selection
Please note that the media within the gas filter fitted in the
filter is capable of adsorbing a wide range of organic
compounds. However, it is the responsibility of the user to
ensure it is suitable for the particular application it is being
used on.
Intended use
This equipment has been designed to extract and filter fume
from a variety of applications. However it is the users
responsibility to ensure the equipment is installed correctly
and is suitable for the application.
This machine must not be used on wet applications or acidic
fumes.
BOFA Technical Service
If a problem arises with your system, or if it displays a fault
code, please refer to the troubleshooting guide section 8of
this manual. If the problem is still not resolved, please:
•Visit our website at
www.bofainternational.com for on-line help.
•Or contact the helpline on
•[phone],
Mon-Fri, 9am-5pm.
Email: [email protected].uk
01
2

Safety Instructions
Warning and Information labels
The following listing details labels used on your unit.
Goggles, Gloves & Mask Label
Meaning: Goggles, Gloves and Masks should be worn while
handling used filters.
Do Not Cover Label
Meaning: Do not cover any louvers or holes adjacent to the
label.
Electrical Danger
Meaning: Removal of panels with this label attached will
allow access to potentially live components.
Warning Label
Meaning: Power should be isolated before the panel with
this label attached is opened/ removed.
Serial Number
For future reference, fill in your system details in the space
provided. The serial number is on the rating label located on
the side/rear of the unit.
Serial Number:
Serial Number Label
*example of label
Location: Rear of unit, next to mains cable.
Meaning: This label contains a variety of information about
the extraction unit, including.
•Company name, Address & Contact number
•Extractor model
•Unit serial number
•Operating voltage range
•Maximum current load
•Operating frequency
•Year of Manufacture
•Relevant approval markings/ logos
PLEASE NOTE: If the equipment is used in a manner not
specified by the manufacturer, the protection provided by
the equipment maybe compromised.
Fire Risk Warning
In the very rare event that a burning ember or spark is drawn into
the fume extraction unit, it may be possible that the filters will
ignite.
Whilst any resultant fire would typically be retained within the
fume extraction unit, the damage to the extractor could be
significant.
It is therefore essential to minimise the possibility of this occurring
by undertaking an appropriate Risk assessment to determine:-
a). Whether additional fire protection equipment should be
installed.
02
2

b). Appropriate maintenance procedures to prevent the risk of
build-up of debris which could potentially combust.
This unit should not be used on processes where sparks could
occur, with explosive dusts and gases, or with particulates which
can be pyrophoric (can spontaneously ignite), without
implementation of additional precautions
It is essential that nozzles or other extraction/ fume capture
devices and hoses/pipework are cleaned regularly to prevent the
build-up of potentially ignitable debris

Before installation
Inner transit packaging removal & unit placement
Before installation, check the extraction unit for damage.
All packaging must be removed before the unit is connected
to the power supply.
Please read all instructions in this manual before using
this extractor.
1. Move the unit to the location where it is going to be
installed and remove the outer packaging. This unit
should be installed in a well-ventilated area.
2. Open the front door and remove the transit foam
from the centre of the unit.
Caution
Due to the weight of the extractor suitable lifting equipment
should be used and with regard to appropriate safety
precautions. (See Appendix for product weight details)
Ensure that 500 mm space is available around any vented
panels on the extractor to ensure adequate airflow.
3. With the unit in position lock the 2 front castors.
Caution
Do not block or cover the cooling vents on the unit,
as this severely restricts airflow and may cause
damage to the unit.
Caution
Under no circumstances should the exhaust
outlet/s be covered as this will restrict the airflow
and cause overheating.
4. Check the filters are located in their correct position
before closing the door and securing the door latches.
Note: The door will not close fully if the Combined filter
has not been secured in place using the internal lever. (As
detailed below)
Unlocked Position
Locked Position
01
3

Installation
The unit has been designed to remove and filter
fume containing potentially hazardous particulate and
gases generated during manufacturing processes. Such
hazardous substances are captured within a multistage
filtration system after which the cleaned air is returned to
the workplace.
Fume Capture Methods
The fume is normally captured by 1 of 3 methods.
•Flexible arm/ Nozzle
•Enclosures
•Cabinets
General Guidelines for a successful installation
•Keep duct run length to a minimum
•Avoid sharp bends / turns in the ductwork
•Avoid multiple bends / turns in the ductwork
•Use a larger diameter duct where able
•Position the capture device as close as possible to
the marking point. (if used on high speed lines,
position the capture device slightly downstream)
Flexible Arm & Nozzle Extraction
The stay put arm should be mounted as close as possible to
the marking point using the horseshoe clips. Unscrew the
push fit connector from the other side of the flexible hose.
Cut the flexible hose to suit the distance back to the
extractor connection and push onto the extractor inlet.
Purge air should be kept to a minimum, where possible, to
prevent the fume being blown away from the nozzle.
High speed lines may need bigger scoops or nozzles both
sides of the product because of the turbulence caused by
the speed of the product.
Moving products
For applications where the product to be marked is moving
past the stationary laser head the capture nozzle should be
positioned as close as possible to the marking area on the
side the product is moving towards.
Enclosures
The extraction hose and nozzle can be attached to the
enclosure surrounding the marking zone provided that the
extraction point is within 50-75mm of the marking point.
Cabinets
Cabinets normally have a 75mm 0r 100mm spigot for fume
extraction. For best performance use the same diameter
hose as the spigot and reduce at the extractor end if
necessary. Keep the hose run as short as possible.
Connection to extraction unit
All ductwork should be installed and connected to the
extraction unit before the system is turned on.
Exhausting filtered air outside
If requested your extraction unit will have been fitted with
an exhaust outlet spigot. This provides a connection point
for exhaust pipework to be fitted. It is important to keep any
ducting to a minimum, in order to reduce back pressure
within the system.
01
4

Installation
Specification
Refer to section 10 01.
Connection to Power Supply
Please follow the above specification when selecting the
power supply outlet for the system, ensure the power
supply is suitable before connecting the system.
Check the Integrity of the electrical power cable, if the
supply cord is damaged the extraction unit should not be
connected to the mains. The supply cord should
only be replaced by a BOFA engineer as an electrical
safety test may be required after replacement.
The system MUST be connected to a properly
earthed outlet.
If your system was ordered with any optional extras
please read section 4.03 before the power connection is
made as additional connections may be required before
power is connected to the extractor.
Connect the power cable to an isolated electrical supply.
The mains socket should be installed near the extractor it
should be easily accessible and able to be switched On/ Off.
The cable run should be arranged so as not to create a trip
hazard.
This equipment shall be mounted in accordance with local
regulation.
Please note –this instruction is for 115V only.
Connecting to supply
Please use table below to connect to mains supply
Cable identifier
Function/ connection to
1
Live
2
Neutral
Green/Yellow
Earth
BOFA recommend that the extraction unit is connected to a
breaker suitable for a 19.5A device. It is also recommended
that the isolation device is located next to the extractor. The
protective conductor shall be mounted close to the mains
supply terminals.
Disconnecting device
This equipment must be connected to a circuit breaker, the
circuit breaker must be easily reached and must be marked
as the disconnecting device for the extractor.
02
4

Installation
Optional added features
The unit can be configured to suit customer specification.
These optional extras would be discussed, arranged and
installed prior to delivery.
(If unsure what features your system is equipped with
please contact the seller with the unit serial number,
(Refer to section 2for location) who will be able to advise
what specification has been supplied.
Remote Stop/Start feature
Enables the extraction unit to be remotely turned On / Off
via an external signal.
This feature can be configured in 3 ways
•DC Voltage input –Range 12-24VDC
•Volt free input –Open / Closed contacts
•Override –Stop / Start feature switched off
Note: Care must be taken to ensure that the system is
correctly wired in order for the extraction unit to function
correctly.
DC Voltage input
This configuration requires the Black & Red cores of the
signal cable (Refer to section 1for location) to be connected
to a known and tested DC power supply, in order to start the
extractor.
The operating voltage for this signal is between 12 &
24VDC. Only voltages within this range should be
connected. Voltages connected outside of this range may
cause irreversible damage to the internal control PCB.
Red cable = V+
Black cable = V-
When the extractor is provided with the correct DC voltage
the motor will start and maintain the set flow rate (Refer to
section 5for how to set the flow) when the DC voltage is
removed the motor will slow down and come to a stop.
The extractor will need to be turned on and be out of
standby mode (See section 5for turning the extractor on) in
order for this feature to operate.
Volt free input
This configuration requires the Black & Red cores of the
signal cable (see section 1for location) to be connected
together, in order to start the extractor. The cables should
be connected to a clean switching device.
When the 2 cables are connected together the motor will
start and maintain the set flow rate (see section 5for how to
set the flow)
when the 2 cables are disconnected the motor will slow
down and come to a stop.
The extractor will need to be turned on and be out of
standby mode (See section 5for turning the extractor on) in
order for this feature to operate.
Override
Enables the extractor to operate fully with or without either
DC voltage input or the Volt free input.
The override feature can be toggled On / Off by a switch
mounted on the internal motor access panel (see below for
switch location)
Switch in “On” position
In this position the extractor will require a start signal (either
Voltage input or Volt free, depending on the requested
specification) to enable the motor within the extraction unit.
Switch in “Off” position
In this position the extractor motor will run without the
requirement for an external start signal. This feature is
useful for engineers carrying out works/ tests on the
extractor without the need for the laser / auxiliary signal
being present.
The power supply unit which is used to provide the 12-
24VDC start stop voltage signal must be protected by
double insulation from mains voltage.
ON OFF
24V Stop Start Function
03
4

Installation
Filter Blocked / System Fail Signal
With this option the system will output a signal to alert the
user when the extractor has failed or when the filters are
blocked.
This feature will not directly stop the extractor from running
correctly, but if fitted this feature should be terminated
correctly before power is applied to the system.
Connection specification
This signal is available via the Green and White cores of the
signal cable. The system will provide a volt free Open /
Closed signal that can be connected to an external interface,
beacon or warning device following the specification below.
•Maximum input voltage: 24V AC
•Maximum current load: 3A @ AC
OR
•Maximum input voltage: 24V DC
•Maximum input load: 3A @ DC
Filter Signal Configurations
There are 3 ways this signal can be configured, as detailed
below.
•Combined signal (standard specification)
•Separated signal
•Reversed separated signal
Combined signal
With this configuration the Filter blocked & System fail
signals will be linked together to give a combined single
output.
When the filters become blocked or the system develops a
fault (Refer to section 8for Troubleshooting & Error codes)
the connection between the Green & White cables will
become “Open”
When the extraction system is running normally the
connection between the Green & White cables will become
“Closed”
Separated Signal
With this configuration the Filter blocked & System fail
signals will be separated to give 2 individual signals.
When the filters become blocked the connection between
the Green & White cables will become “Open”
If the system develops a fault (Refer to section 8for
Troubleshooting & Error codes) the connection between the
Blue & Yellow cables will become “Open”
When the extraction system is running normally the
connection between the (Green / White) & (Blue / Yellow)
cables will become “Closed”
Reversed Separated Signal
With this configuration the cable function will remain the
same as the Separated signal option, but the signal given
will be reversed.
For blocked filters the connection between the cable cores
will be “Closed”
For system faults the connection between the cable cores
will be “Closed”
For system OK the connection between the cable cores will
be “Open”
Combined Signal
Separated Signal
Compressor option
If a compressor has been fitted to the extraction unit,
connect the compressor hose, to the extractor compressor
outlet (Refer to section 1for location) and connect the
opposite end to the laser. Refer to laser installation
instructions.
EXTRACTOR
UNIT
Open/Closed circuit
given on condition of
filters/Unit
EXTRACTOR
UNIT
Open/Closed circuit given
on condition of filters
Open/Closed circuit given
on condition of Unit
04
4

Installation
Optional Added Feature: Door and Pre Filter Interlock
With this option the system will not function if the front
door has been left open. There is a switch located on the
internal cam shelf next to the combined filter handle. To
enable the system to function, the front door must be
closed and the latches secured.
A second switch is located in the extraction unit behind the
pre filter.
If there is no pre filter fitted, the system will prevent the
extraction unit from starting up. A pre filter will need to be
installed (see section 6.02) and the front door closed before
the unit is able to start.
This equipment shall be mounted in accordance with local
regulation.
05
4

Operation
Turning extraction unit On
There are 2 stages to powering up your extraction unit.
Firstly the main isolation switch must be switched to the
“On” position (Refer to section 1for switch location) by
depressing the Green side / (I) of the switch.
This will place the extraction unit in Standby mode,
indicated by the front panel power button glowing Red.
If the unit has a powder coated finish then the top side of
the switch should be depressed to power the unit.
To start the extraction unit press the front panel power
button (refer to section 1 for switch location) the button will
change from Red to Green indicating the extraction unit is
now fully On.
It is recommended that the rear isolation switch is left in the
On position and the front standby switch is used to toggle
the extractor On / Off.
Changing the display units
The Airflow and temperature readings can be displayed in 2
ways.
1. Temperature displayed as oC
Airflow displayed as m3/h
OR
2. Temperature displayed as oF
Airflow displayed as CFM
The display value can be changed by pressing the “Enter”
button once.
1)
2)
Powder Coated
Stainless Steel
Standby
On
01
5

Operation
Setting the desired airflow
The system features automatic flow control. This enables
the user to set the required airflow rate, then over time as
the filters begin to block the motor will automatically begin
to increase in speed to compensate for any loss in
performance caused by the added restriction of the partially
blocked filters.
The extractor and all pipe work must be fully
installed and connected before the airflow is set.
To set the airflow
(The airflow can be set between 300-850m3/h)
1. Press and hold the “Enter” (middle) button (Refer
to section 1for button location) for 3 seconds, or
until all 3 button lights flash green.
2. Release the Enter button, the system is now in set
mode. Press either the Up or Down button to
adjust the airflow accordingly.
Real time airflow is displayed on the LCD screen,
Refer to section 1 for Display information)
3. Once you have your desired airflow, leave the
controls, after around 10seconds the flashing
buttons will illuminate constantly to confirm the
airflow is stored.
The set airflow will now be maintained throughout the life
of the filters. When the extraction unit can no longer
maintain the set airflow an alarm will be given and the
display will indicate which filter should be changed.
1)
2)
3)
02
5

Operation
Airflow Auto Adjust (first installation only)
When first setting the airflow on your new extraction unit
the system will detect if the desired airflow is achievable
with the installation that has been connected to the
extraction unit.
If the installation is causing too much restriction for the
desired airflow to be reached, the Auto Adjust feature will
be activated. The procedure events are listed below.
1) The 3 buttons will begin flashing Red along with the
airflow setting on the LCD screen.
2) The airflow setting on the screen will drop to display the
highest airflow that can be achieve.
3) The airflow will stabilise and the buttons will turn green to
show the airflow has set.
03
5

Maintenance
Maintenance UK
It is a legal requirement, under regulation 9 of the COSHH
regulations that all local exhaust ventilation systems are
thoroughly examined and tested at least once every 14
months (typically carried out annually). The approved code
of practice recommends that a visual check should be
carried out at least once a week.
COSHH requires the annual inspection and testing to be
carried out by a competent person and specifies that
documentation results are recorded in a log.
Contact the seller for more information about inspection
and certification.
Maintenance General
User maintenance is limited to cleaning the unit and filter
replacement, only the manufacturers trained maintenance
technicians are authorised to carry out component testing
and replacement. Unauthorised work or the use of
unauthorised replacement filters may result in a potentially
dangerous situation and/or damage to the extractor unit
and will invalidate the manufacturer’s warranty.
Cleaning the unit
The stainless steel units should be cleaned with a
proprietary stainless steel cleaner, in accordance with the
manufacturer’s user instructions
The powder coat finished units can be cleaned with a damp
cloth and non-aggressive detergent, do not use an abrasive
cleaning product as this will damage the finish.
The cooling inlets and outlets should be cleaned once a year
to prevent build-up of dust and overheating of the unit.
Replacing Filters
The system constantly monitors the condition of the
individual filters. As the filters block the LCD display will
show the relevant filter symbol filling up. (see section 1 for
LCD details) Each filter symbol fills up in 5% increments,
when the filter icon is filled that particular filter will need
replacing.
Pre Filter blocking Combined Filter Blocking
A log of the changes should be maintained by the user.
The filters require attention when the display shows the
filter blocked icon/ filter output signal (if fitted) or when the
extractor no longer removes fume efficiently.
It is recommended that a spare set of filters are kept on site
to avoid prolonged unit unavailability. Part numbers for
replacement filters can be found on the filters fitted in your
system.
To prevent overheating, units should not be run with a
blocked filter condition, or with dust obstruction of Inlets /
Outlets.
75% filter blocked indication
When the filters become 75% blocked the buttons on the
front of the extraction unit will turn from Green to Amber
and if fitted the system will output a signal to indicate this.
At this time it is recommended spare filters are available as
a change may be needed shortly.
TIME
01
6

Maintenance
Pre Filter Replacement
Refer to section 2 02 for PPE requirements.
The Pre filter needs replacing when the display flashes
between the 2 images shown below, at this point the
buttons will glow Red and if fitted the filter blocked signal
will be given.
To remove and replace the Pre filter follow the procedure
detailed below.
1. Isolate the electrical supply to the extractor
2. Undo the catches on the front of the unit and open
the door.
3. The Pre filter is the lower of the 2 filters (refer to
section 1for filter location) using the handle on the
front of the filter, pull it out of the unit.
4. Once removed it is recommend that the used filters
are bagged and sealed.
5. Slide the new filter into position making sure it is
pushed all the way in and is located correctly on the
spigot in the back of the unit.
6. Close the door and fasten the 2 latches.
Combined Filter Replacement
The Combined filter needs replacing when the display
flashes between the 2 images shown below, at this point the
buttons will glow Red and if fitted the filter blocked signal
will be given.
To remove and replace the Combined filter follow the
procedure detailed below.
Warning
The combined filter is very heavy (Over 40Kgs) therefore
the procedure below must be carried out by 2 people lifting
together.
1. Isolate the electrical supply to the extractor
2. Undo the catches on the front of the unit and open
the door.
3. The Combined filter is the higher of the 2 filters
(refer to section 1for filter location) rotate the lever
below the filter through 180oto lower the
combined filter.
4. Using the handle on the front of the filter, pull it out
of the unit being careful to support it as it comes
free as it is heavy.
5. Once removed it is recommend that the used filters
are bagged and sealed.
6. Slide the new filter into position making sure it is
pushed in all the way.
7. Rotate the lever back through 1800to raise the
filter into position.
8. Close the door and fasten the 2 latches
9. Reconnect the power supply
Both filters MUST be fitted when the extractor is in use, if
the combined filter is not installed correctly the system
will not allow the motor to start.
02
6

. System Display
Display Features
The display has the ability to display all the faults associated
with your extraction unit. The image below shows an
example of some of the fault icons that may appear in the
alarm window of the LCD display.
Visual Alarms on the system
The system can visually display a wide range of alarms on its
LCD panel. The visual displays, meanings and solutions are
detailed below. All alarms will trigger the system alarm
interface output signal and the inbuilt audible buzzer, if
fitted/ activated.
Over Temperature Alarm
If the system detects an internal temperature greater than
60oC then it will automatically shut down the extractor to
prevent damage to components within the extractor.
Once the internal temperature has dropped by 50C the
extraction unit will be able to restart.
To restart the extractor after an over temperature alarm the
unit needs to be placed in Standby mode then powered on
again.
Hose blocked alarm
The system features a 2 stage Hose blocked alarm.
•Partial hose blockage
•Full hose blockage
Partial hose blocked alarm
This alarm will become active when the system detects a
part blockage in the installation. The system interprets a
partial blockage as a vacuum spike within the ductwork but
is only a partial blockage as the extractor is still able to
maintain its set airflow.
During this time it is normal to hear the motor increase in
speed. The blockage will need to remain in the ductwork for
over 5 seconds before the alarm is given.
Full hose blockage
This alarm will become active when the system detects a full
blockage in the installation. The system interprets a full
blockage as a vacuum spike within the ductwork and is
considered a full blocked as the extractor cannot maintain
the set airflow with the blockage present.
During this time it is normal to hear the motor increase in
speed. The blockage will need to remain in the ductwork for
over 5 seconds before the alarm is given.
To remove the blockage, isolate the extraction unit from the
mains, remove the flexible hose, locate and remove the
blockage then reattach the hose as previously installed.
01
7